THE THIRD PART INSPECTION FOR VALVES

The Third Party Inspection for Valve article provides you with information about valve
testing and valve inspection in the manufacturing shop. It is particularly suitable for
the inspection of Gate, Globe, Ball and Check valves.
You may need to review this article along with the following article:
Inspection and Test Plan for Valve

This content guides you through all necessary stages in the production of the
industrial valves, including the inspection of raw material to the final inspection,
preservation, packing, and dispatch to site.
You need to take this point into account: this article is written for a typical valve and
might not be detailed for special cases.
This content may be useful for second party inspectors, valve manufacturer quality
control personnel, engineering companies, and purchasers, as well.
All valve inspection and testing is done against the approved drawings, purchase
order specifications, purchasers or company standards, and within the practices and
rules of the country, state or province and any government decrees, laws, ordinance
or regulation as may apply.
As a general guide, all valves over 8" NB will normally be individually witnessed on
test. With very large or special valves, such inspection may be extended to detailed
component inspection of major components.
Such detail inspection will always apply to valves intended for high pressure steam,
cryogenic, nuclear or other critical service, and in such instances, will extend to
valves smaller than 8" NB.
The applicable codes and specifications for a valve that is under the construction
process is:

Design code

Purchase order specification

Purchaser's standards

Approved drawings

and the applicable codes and standards are:

API 598

API 6D

API 594

ASME / ANSI B16.5

API 600, 602, 603, 604

The applicable codes and standards may be based on other international standards.
This content is general and can be useful even if the design code is different from the
API Code.
Required Documents for Third Party Inspector Review:
The list of documents normally is agreed upon in the Pre-Inspection meeting, which
is held several weeks before the actual commencement of the inspection work.
The parties that participate in this meeting are the manufacturer, purchaser and third
party inspection agency representatives.
This is already explained in the Inspection and Test Plan for Valve article.
These are the list of documents that are normally agreed upon to be presented to the
inspector:

Valve Purchase Order or Contract

Valve Manufacture Quality Control Plan

Valve Inspection and Test plan

Valve Data Sheet

Valve Approved Drawings

Valve Material Test Reports

Valve Welding Specification Procedures (WPS) and Procedure Qualification

Records(PQR)

Valve Welders Qualifications Reports

Valve NDE Procedures

Valve NDE Personnel Qualifications Reports

Valve Heat Treatment Procedure

Valve Calibration Certificates for Test Equipment

Valve Hydrostatic Testing Procedure and Water Quality Document

Valve Preparation and Painting Procedure

Valve Preservation, Packing and Shipping Procedure

Valve Packing List

Third Party Inspection for Valve - Material Inspection

The first actual inspection work in the valve is the raw materials inspection.
The original or authenticated copies of mill certificates of material normally are
available at the manufacturer's premises.
The third party inspector examines these certificates for compliance with
specifications, and where appropriate, drawings.
The review includes checks on:

Certificate No.

Heat or cast No.

Chemical composition.

Mechanical properties.

Heat treated condition.

NDE applied and results.

Surface finish

This covers body stem material, shell material, trim materials, gland materials, antifriction materials, ball, wedge or flap materials, operating components, support
material, well end, flanges and any other specified component.
Then the inspector witnesses the materials identification on the certificates against
the materials marking. It is also necessary to check these with the valve drawing
datasheet, material list and other specifications as appropriate.
Visual inspection for surface finish and probable defects is done and dimensional
compliance with specification need to be controlled, as well.
When third party inspector carries out the material inspection, then provides the
inspection visit report (IVR), the report contains the following items:

Confirmation of satisfactory document review

Record of the endorsement of certification reviewed/witnessed

Record of all non-conformities

Record of any tests witnessed and the result

Third Party Inspection for Valve - Welding Inspection

When the valve material inspection is carried out, and the results were satisfactory or
non-conformities were closed by remedial action, then the valve manufacturer will
start fabrication.
The third party inspector checks the following points on the valve based on the
inspection and test plan (ITP), which has already been agreed upon between the
purchaser and the valve manufacturer.
The inspection scope is determined in the ITP. Some purchasers prefer to have
stringent controls and assign the TPI for more hold or witness points for inspection
and test activities, and some others prefer less hold or witness points and assign
the TPI much more work in the review document.
This depends in the inspection budget, which purchasers assign for inspection. Much
more inspection will have a much larger cost and less risk, and conversely, less
inspection will have less cost but more risks.
For more details, review the Inspection and Test Plan for Valve article. There is draft
ITP in this article which I believe it is the best practice for valve inspection.
The third party inspector carries out visual and dimensional check to ensure
compliance with WPS and specification. Where specified, weld bevels need to be
examined by MT or PT after grinding/machining.
Edges and weld bevels need to be clean, dry and free from surface defects,
laminations, cracks, voids, notches, etc.
These are causes for rejection unless suitable/satisfactory remedial action can be
taken. Welding repairs to bevels are not permitted, without approval from the client.
Inspectors need report excessive or serious defects.
Following items are taken into account when third party inspector making inspection
on the valve welding:

Cleanliness and fit up accuracy of preps.

Roundness of form of components.

Application of preheat.

Welding in progress.

Cleaning of welds.

Completion of test coupons, (where specified)

NDE. Results shall meet specifications or code requirements.

Hardness tests - when specified in the contract

Impact tests- when specified in the contract

If the third party inspector is not in the hold or witness point in the ITP for this
inspection stage, then he/she will review the valve manufacturer quality control report
in his/her coming visit or on the final inspection day.
Third Party Inspection for Valve - Post Weld Heat Treatment
Third party inspector carries out dimensional check and PWHT control as specified.
When PWHT has been completed then portable hardness measurement may be
used to establish hardness of material, heat affected zone or welds, as may be
specified.
Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the valve manufacturer quality control
report in his/her coming visit or on the final inspection day.
Third Party Inspection for Valve - Visual and Dimensional Checking
Third party inspector controls following points:

To verify that the model and various features and components comply with the
purchase order description and valve specification and drawings as
applicable.

To verify that the dimensions of valves, flanges, flange drilling, bore, stem,
threading, wall thickness and any other dimensions, as applicable, comply
with the requirements of the specification and other.

Witnessing required pressure tests.

Witnessing functional test of actuator on valve, when actuators are specified.

Radiographic examination and other NDE in accordance with the applicable

references noted above.

Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the valve manufacturer quality control
report in his/her coming visit or on the final inspection day.
Third Party Inspection for Valve - Low Pressure Air Test
when required by the contract or purchase order, the third party inspector witnesses
low pressure air test and pays attention to the following points:

Specialized testing of seats, the seals, by-passes, etc., may be required by

purchase order.

A minimum of 2 gauges with correct working ranges are used. The calibration
of the gauges needs to be checked.

Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the valve manufacturer quality control
report in his/her coming visit or on the final inspection day.

Third Party Inspection for Valve - Hydrostatic Testing

The third party inspector checks all previous items have been accepted by authorised
bodies and witness hydrostatic test and verify following points:

Body tests, high pressure closure tests, back seat tests as detailed in
applicable procedure and code specification.

Calibration status and correct working ranges of gauges. A minimum of 2

pressure gauges are attached to item under test.

Adequate provision for venting of high points and draining of the test medium
are provided.

Test pressure is applied as directed by procedure or code until test limiting

pressure is reached. During hold period, a methodical check for leaks is
conducted.

Test pressures, metal and water temperatures are recorded.

Water quality is as specified.

Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the valve manufacturer quality control
report in his/her coming visit or on the final inspection day.
Third Party Inspection for Valve Post Hydrostatic Testing

After depressurisation, valve components are drained and dried to meet

specified requirements.

Stamping of Inspection authority stamps, are carried out in approved area, as

required by client/code.

Stamps used need to be low stress type.

Application of desiccant/preservative need to be as directed in client's

specification.

Third Party Inspection for Valve Final Inspection

All valves need to be checked for cleanliness and dryness by third party inspector.
Nozzle, outlets, flanged or butt welded, saddle, bracket locations and orientations
against assembly drawings are controlled and operation of valve indicator and
correct functioning also be checked.
Third Party Inspection for Valve - Name Plate Checking
The third party inspector checks the content in accordance with the approved
drawings and specifications and make sure it is stamped in accordance with the code
requirements.

Third Party Inspection for Valve - Painting and Coating

Surface preparation for painting is checked for the following points, according to
specification by third party inspector:

Cleaning method (Blast or scraping and wire brushing)

Preparation grades

Freedom from weld spatter, blow-holes and other defects

Dry film thickness is checked according to specification

Surface condition need to be free from pin-holes, runs damage and other
discontinuity
Third Party Inspection for Valve - Spare Parts, Loose Items and Accessories
Spare parts, loose items and accessories are checked visually for their dimensions,
materials, workmanship and quantity, according to the purchase order specification.
Test marks and tags are checked for correct identification.
Third Party Inspection for Valve - Reporting:

The third party inspector provides an Inspection Visit Report (IVR) after each
visit, as well as a final report summarizing the activities carried out during the
valve production in accordance with the contract requirements and circulated
within the time limits specified in the contract.
The report is in the format required by the client and clearly indicates final
acceptance or rejection of the valve.
Third Party Inspection for Valve - Release Note:
When required by the contract or purchase order, a release note is issued by the
third party inspection agency and given to the manufacturer when the valves have
been accepted.
Third Party Inspection for Valve - Packing, Marking and Shipping:
The following points are checked by the third party inspector:

Cleanliness and dryness of components

Rust prevention for all machined surfaces

Protection for cover for all opening and protruding parts

Packing style and suitably for overseas transportation

Shipping marks and other markings

Third Party Inspection for Valve - Final Book (Dossier)

The following final documents are reviewed and signed off by the third party
inspector:
As built drawings, Manufacturer's data reports, Material certificate or certified mill test
reports for all pressure parts, Material list or map, Welder record for each weld, Heat
treatment records (Temperature-time record chart during PWHT), Dimensional
record, NDE records, Pneumatic test record, Hydrostatic test record, Hardness test
record, Final assembly checks, Marking inspection report, Packing list, Spare parts
list